Folding apparatus

ABSTRACT

A folding apparatus for folding a plurality of sheets of multiple lengths such as mail statements, which includes a plurality of folder rollers, one or more folder gates, and a kicking plate associated with one of the folder gates. An input transport system provides statements to the folder rollers, and an exit transport system receives folded statements therefrom. A system controller monitors movement of statements through the folder rollers and folder gates of the apparatus by a plurality of sensors, and directs operation of the kicker gate at the appropriate time to push or eject the folded statements from the folder rollers. The action of the kicker plate prevents undesirable folding of the tips of shorter sheets in the statement while folding the longer sheet or sheets of the statement.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The invention pertains generally to systems and methods for foldingpaper sheets, and more particularly to a folder ejector apparatus forhigh speed folding of a plurality of stacked or collated sheets or pagesfor envelope insertion wherein one or more of the plurality of sheets islonger than the others.

2. Description of the Background Art

Periodic billing operations, such as the preparation and mailing ofmonthly billing statements to customers, require quick and efficientpreparation and processing of large numbers of statements. Such billingstatements each generally include a plurality of pages, sheets, or formswhich must be printed, separated, organized, collated, folded, andinserted into envelopes.

Generally, each billing statement includes at least one page or formwhich is of greater length than the other pages in the statement. In onestandard billing format, for example, the first or outer page of thebilling statement is printed on an 8.5" by 14" sheet, while theremaining, inner pages in the statement comprise 8.5" by 11" sheets. Thelonger form generally includes a detachable portion that is removedalong a perforation or indentation line by the billing recipient toleave an 8.5" by 11" sheet which is retained by the recipient forrecord-keeping. The detached portion, together with a payment, is thenreturned by mail to the biller.

A variety of folding systems and devices for mail preparation are knownand used for high speed folding of a plurality of sheets or pages in amanner suitable for subsequent envelope insertion. Typically, a mail orbilling statement is folded in half or in thirds by a buckle folder orother conventional folding device to provide a folded statement suitablefor insertion into standard billing envelopes.

An important drawback in the currently known folding systems anddevices, however, is the inability to accurately fold statementscontaining a plurality of sheets with one or more sheets of greaterlength than the others, as in the aforementioned standard billingformat. When such a statement has been folded once to produce a folded8.5" by 5.5" packet, there are still an additional three inches of thelonger, outer sheet or form that protrude out from the 8.5" by 5.5"folded packet and which must be folded in order to fit into theenvelope. A conventional buckle folder, in folding such a billingstatement, cannot reliably fold over the three inch long detachableportion or tab of the longer, outer sheet into the 8.5" by 5.5" foldedstatement or packet without also causing unwanted folding of the tips ofthe inner, shorter sheets. When a plurality of 8.5" by 11" inner, sheetsand one or more longer, outer sheets are registered along their frontedges during collation and folded over, the back edges of the inner 8.5"by 11" sheets tend to extend out slightly past the eleven inch mark ofthe longer outer sheet in a shingling effect. Thus, as the extra portion(typically three inches) of the longer, outer sheet is folded over by aconventional buckle folder, the tips of the inner sheets are alsofolded. The folded tips of the inner statement detract from the overallappearance of the statement, which can cause customer dissatisfaction.The folded tips also interfere with the envelope insertion operation forthe billing statements, since the folded tips may catch or jam in themachinery associated with conventional high speed envelope insertion,causing system shutdown and delay while the jam is cleared.

Accordingly, there is a need for a folding apparatus which can fold abilling statement having one or more sheets which are longer than theothers without folding the tips of the shorter sheets, which performsfolding operations quickly and efficiently, and which avoids systemshutdowns due to improperly folded statements. The present inventionsatisfies these needs, as well as others, and generally overcomes thedeficiencies present in the background art.

SUMMARY OF THE INVENTION

An object of the invention is to provide a folding apparatus which canaccurately fold a plurality of pages or sheets of multiple lengthswithout causing unwanted folding of the tips of the shorter sheets.

Another object of the invention is to provide a folding apparatus whichoperates quickly and efficiently.

Still another object of the invention is to provide a folding apparatuswhich is operated by a system controller which monitors folding of theplurality of sheets by sensor means.

Yet another object of the invention is to provide a folding apparatussuitable for use in large volume, high speed processing of mail orbilling statements.

Further objects of the invention will be brought out in the followingportions of the specification, wherein the detailed description isprovided for the purposed of fully disclosing the invention withoutplacing limits thereon.

The subject invention is a folding apparatus which quickly andaccurately folds mail or billing statements containing a plurality ofsheets of multiple lengths. In general terms, the invention comprises aplurality of roller means for folding sheets, a plurality of gate means,adjacent to the roller means, and means for ejecting folded sheets outof the gate means and roller means. The invention also preferablycomprises input means for providing sheets to the plurality of rollermeans, and output means for removing folded sheets from the plurality ofroller means. The invention generally operates under the direction ofcomputer control means, and preferably includes sensor means, interfacedwith the control means, for detecting the location of sheets relative tothe plurality of roller means and plurality of gate means.

By way of example and not of limitation, the roller means generallycomprises a plurality of conventional folder rollers (such as thosefound in a traditional buckle folder) which may be adjustably positionedrelative to each other, depending upon the type of folding operation tobe carried out with the subject invention. The gate means preferablycomprises one or more conventional folder gates and their associatedgate assemblies, and are positioned adjacent to the folder rollers. Thefolder gates may be positionally adjusted according to a particularfolding operation. The means for ejecting folded sheets out of theroller means and/or gate means preferably comprises a kicker platecoupled to an actuator, with the actuator being associated with one ofthe folder gates. The input means and output means preferably comprisesstandard belt and pulley driven document transport systems which aresuitably positioned to provide sheets into the folder rollers andreceive folded sheets therefrom. The control means is preferably asystem control computer which directs actuation of the kicker plate. Thesensing means are interfaced with the control means and generallycomprise an encoder for timing of the kicker gate actuation based onrotational values, as well as a plurality of photocell sensors orequivalent devices located adjacent the input means, output means, andfolder rollers, which track and verify the position of statements duringfolding.

In operation of the subject invention, the input document transportsystem provides a plurality of sheets, which have preferably beenorganized and collated, to the folder rollers. The plurality of sheetswill generally be a mail or billing statement having at least one sheetwhich is generally longer than several shorter sheets, with the leadingedges of the sheets being aligned or registered previously duringcollation. The sheets are received by a pair of folder rollers anddirected along a folding path towards a first folder gate. As theleading edges of the sheets come into contact with the first foldergate, movement of the sheets in the direction of the gate is blocked,and the action of the folder rollers causes the sheets to buckle andfold. The folder rollers and folder gates may be adjustably positionedto control the folding path of the sheets and thus the location of thefolds and number of folds produced. Preferably the folder rollers andfolder gates are positioned to produce a folded packet which isgenerally folded in half, with the end of the longer sheet or sheetsprotruding out of the packet, as described above. The folded packet isthen directed by a series of folder rollers, which passively engage orgrip the statement, along the folding path towards the kicker plate orother ejecting means, upon which the folded edge of the packet comesinto contact. The kicker plate blocks travel of the folded packet. Thekicker plate, at the direction of the system controller, then ejects thefolded statement, causing the protruding portion of the longer sheet orsheets to buckle and fold, preferably along a perforation, rather thanbe forced back into the folder rollers. The protruding portion of thelonger sheet of the statement is thus folded by the ejecting action ofthe kicker gate. Following the action of the kicker gate, the shortersheets of the statement are not gripped by the folder rollers, andtherefor do not undergo unwanted folding. The control means tracks theposition of the statement by monitoring the encoder, which informs thecontrol means of the position of the machine cycle of the folderapparatus, and thus the position of the statement. The photocell sensorverify that statements have entered and exited the apparatus.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be more fully understood by reference to thefollowing drawings, which are for illustrative purposes only:

FIG. 1 s a side view of a folding apparatus in accordance with thepresent invention.

FIG. 2 is a side view of the folding apparatus of FIG. 1 showing afolding path.

FIG. 3 is a side view of the folding apparatus of FIG. 1 illustratinggenerally the folding of a statement along a folding path.

FIGS. 4A-4E show a billing statement undergoing steps of one foldingoperation which may be carried out with the present invention.

FIG. 5 is a flow diagram indicating a general control scheme for thefolding apparatus comprising the present invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring more specifically to the drawings, for illustrative purposesthe present invention is embodied in the folding apparatus which isshown generally in FIG. 1 through FIG. 3, the folding scheme shown inFIGS. 4A-4E, and the flow diagram of FIG. 5. The invention is describedin terms of folding a standard billing statement which includes onelonger sheet (usually the bottom or lower sheet, but the position mayvary), together with several shorter or sheets, with the statement beingfolded for insertion into standard billing envelopes. However, as willbe readily apparent to persons of ordinary skill in the art, a varietyof folding operations and schemes, involving folding of multiple sheetsof varying lengths and widths and which are arranged in many ways, maybe carried out with the present invention. Similarly, it should bereadily understood that the apparatus may vary as to configuration andas to details without departing from the basic concepts disclosedherein.

Referring first to FIG. 1 through FIG. 3, there is shown generally afolding apparatus 10 in accordance with the present invention whichquickly and efficiently folds statements containing pages or sheets ofmultiple lengths. The term "statement" as used in this disclosure refersgenerally to a stack or packet of paper sheets, forms, or pages whichhave been organized and collated in a manner suitable for folding andinsertion into envelopes. The folding apparatus 10 includes a pluralityof roller means for folding sheets, which, in the preferred embodiment,comprise conventional folder rollers 12a, 12b, 12c, 12d, 12e, and 12f.Folder rollers 12a-12f, which are shown in end view in FIG. 1 throughFIG. 3, are generally elongated cylinders of suitable length for foldingpaper sheets, which typically have widths of 6 and 5/8", 8.5" or otherstandard widths. Folder rollers 12a-12f have outer surfaces (not shown)with traction means for engaging paper sheets, as is standard in theart. Folder rollers 12a-12f are mounted on axles 14a-14f respectively,which are rotationally driven by conventional means. Standard adjustmentmeans for positioning folder rollers 12a-12f are also generally includedwith the invention, and are omitted from the drawings for reasons ofclarity.

The subject invention also comprises one or more gate means for foldingsheets. A first gate means is shown as a folder gate 16 mounted in aconventional folder gate assembly with frame members 18a, 18b andadjustment means for positioning folder gate 16, shown generally as gateadjustment knobs 20a, 20b, which are mounted by screws 22a, 22b to framemembers 18a and 18b respectively. The adjustment means for positioningfolder gate 16 also generally comprises belts (not shown) which connectknobs 20a, 20b with folder gate 16 so that rotation of knobs 20a, 20bcauses folder gate 16 to translate along frame members 18a, 18b. Othercommon adjustment means for positioning folder gate 16 may also be usedwith the invention. A second gate means includes folder gate 24 which,like the first gate means, is mounted in a conventional gate assemblywith frame members 26a, 26b and gate adjustment knobs 28a, 28b mountedrespectively thereon by screws 30a, 30b. Additional gate means forfolding sheets into various configurations may be included with theinvention, and are shown generally as gate assemblies 32, 34, which areidentical to the first and second gate means as described above, andfrom which the details have been omitted for reasons of clarity. Meansfor ejecting folded sheets or statements out of a gate assembly andthrough a plurality of rollers are generally associated with one of thegate means, as described further below.

Input means for providing sheets or pages to folder rollers 12a-12f aregenerally included with the invention, and preferably comprise aconventional document transport system for paper sheets which includesupper pulleys 36a and lower pulleys 36b, and upper belts 38a and lowerbelts 38b. Upper and lower belts 38a, 38b form continuous, elongatedloops which are associated with upper and lower pulleys 36a and 36brespectively at one end as well as a corresponding set of pulleys (notshown) at the other end of the elongated loops. Upper and lower pulleys36a, 36b are positioned adjacent to each other and are spaced apartvertically at an appropriate distance so that standard paper sheets maybe transported between upper and lower belts 38a, 38b, whichfrictionally engage the sheets. Upper and lower pulleys 36a, 36b andupper and lower belts 38a, 38b are rotationally driven by standard means(not shown), and are positioned so that the action of the upper andlower belts 38a, 38b transports or inputs paper sheets into folderrollers 12a-12f. Upper and lower belts 38a, 38b are generally made froman elastomeric material suitable for frictionally engaging paper sheets.

Other input means are also contemplated for use with the presentinvention. For example, paper sheets may be directed into folder rollers12a-12f through a chute or channel by means of compressed air jetsand/or vacuum sources, or other mechanical input means commonly used inthe art. Compressed air jets and/or vacuum sources may additionally beused in conjunction with the belt and pulley input transport systemdescribed above, if desired.

Also included with the invention are means for ejecting or pushingfolded sheets out of at least one gate means and through one or morefolder rollers 12a-12f, in order to prevent undesired folding of thetips of the shorter sheets of a statement, as described above. In thepreferred embodiment, the ejecting means comprises a kicker plate 40which is slidably associated with the frame members 26a, 26b of thesecond gate means. Kicker plate 40 is moved or driven by suitableactuating means, which preferably comprise a compressed air actuator 42,which is coupled to kicker plate 40 by plunger rod 44 and connectormember 46. Compressed air is supplied to actuator 42 via air line 48which is connected to a compressed air source (not shown). Actuator 42is attached to a base 50, with base 50 being mounted on frame member26a. Actuator 42 and base 50 may alternatively be mounted directly ontogate 24. Actuator 42 may be driven by other means such as vacuum,electromagnetic force, and the like.

The ejecting means of the subject invention may alternatively or incombination comprise a block, bar, forked member, or other structuresuitable for ejecting folded sheets. While kicker plate 40 is describedand shown generally as associated with frame members 26a, 26b of thesecond gate means, this particular arrangement should not be consideredlimiting. Kicker plate 40 and actuator 42 could alternatively beassociated with another gate means of the invention, or could be mountedon any suitable supporting structure wherein kicker plate 40 ispositioned to push folded sheets through certain ones of the pluralityof folder rollers 12a-12f as required to prevent unwanted folding of thetips of shorter sheets in a statement. Mounting the kicker plate 40 orother ejecting means directly onto the frame members of one of the gatemeans in the manner shown facilitates the construction and operation ofthe invention, and thus is the presently preferred arrangement. Kickerplate 40 is shown associated with frame members 26a, 26b of the secondgate means in order to illustrate the use of the present invention withthe particular folding operation described above. The location of kickerplate 40 or other ejecting means may thus be varied relative to folderrollers 12a-12f, depending upon the particular folding operation whichis to be carried out with the invention.

Means for positionally adjusting kicker plate 40 are generally includedwith the subject invention, to allow control of the amount or level ofpushing or ejection provided by kicker plate 40 to a folded document. Atranslational adjuster 52, associated with connector member 46, may beused to provide accurate positioning of kicker plate 40. Base 50 couldalso include sliding adjustment means for positioning actuator 42 andkicker plate 40. If base 50 is mounted directly onto gate 24, theposition of kicker plate 40 and actuator 42 may be adjusted by thepositioning of gate 24 by turning adjustment knobs 28a, 28b, asdescribed above. Other adjustment means commonly used in the art mayalso be used for positionally adjusting kicker plate 40.

Folded sheets are removed from folder rollers 12a-12f by output meanswhich preferably comprise a conventional document transport system withupper pulleys 54a, lower pulleys 54b, and upper belts 56a and lowerbelts 56b. As with the input transport system described above, beltsupper and lower belts 56a, 56b form continuous, elongated loops whichare associated with upper and lower pulleys 54a and 54b respectively atone end as well as a corresponding set of pulleys (not shown) at theother end. Upper and lower belts 56a, 56b frictionally engage the foldedsheets or statements received from folder rollers 12a-12f, and transportthem to other downstream mail processing operations, such as insertionof the folded statements into envelopes and postage metering.

The invention generally operates under the direction of computer controlmeans, which is preferably a system controller computer as discussedfurther below in reference to FIG. 5. Preferably, sensor means, whichare interfaced with the control means, detect the position or locationof sheets before and after folding relative to the folder rollers12a-12f, folder gate 16, and kicker plate 40. The sensor meanspreferably comprising encoder means such as a rotational shaft encoder61, shown associated with pulley 36a, is included to provide timinginformation to the control means based on rotational values. Interfacecable 63 connects encoder 61 with the control means. Generally pulleys36a, 36b of the input means, pulleys 54a, 54b of the output means, andfolder rollers 12-12f are driven by the same power source, such as anelectric motor (not shown), and the monitoring by encoder 61 of therotational angle of pulley 36a provides information for the overallmachine cycle of the folding apparatus 10. Monitoring of the machinecycle of the folding apparatus 10 in this manner allows the controllermeans to activate kicker plate 40 at the correct time. Encoder 61 mayalternatively be located on one or more of the folder rollers 12a-12f,or on one of the other pulleys 36b, 54a, 54b of the input or outputmeans. The encoder means may also be included within the motor (notshown) that drives the folding apparatus 10, with the motor suitableinterfaced with the control means.

The sensor means also preferably comprises a first photoemitter andphotodetector 58a, 58b positioned generally adjacent to the input meansof the invention, and a second photoemitter and photodetector 60a, 60bpositioned generally adjacent to the output means of the invention. Theinvention, however, may be operated without such sensing means.

Referring now to FIG. 4A through FIG. 4E as well as FIG. 2 and FIG. 3,the use of the present invention for folding a standard billingstatement with one long sheet and one shorter sheet is generallyillustrated. As stated above, the invention may be used for a variety offolding operations involving various collections of sheets or pages ofmultiple widths and lengths. Thus, the example described herein andshown generally in FIGS. 4A through 4E is merely for illustrativepurposes.

Referring first to FIG. 2, there is shown a folding path 62 inaccordance with the illustrative example mentioned above. Folding path62 is obtained by adjusting the positions of folder rollers 12a-12f andfolder gate 16 and kicker plate 40 generally to the positions shown inFIG. 2 and FIG. 3. Different positioning of the folder rollers 12a-12fand the folder gate means may be used for different folding operations.

Referring more particularly FIG. 2, FIG. 3, and FIG. 4A through FIG. 4E,there is shown a mail statement 64 undergoing folding according toconfiguration of folder rollers and folder gates shown in FIG. 2 andFIG. 3.

In FIG. 4A, statement 64 is shown to include a longer sheet 64a and ashorter sheet 64b. Statement 64 is provided to the folder rollers12a-12f by the belts 38a, 38b and pulleys 36a, 36b of the input means,with sheets 64a, 64b registered or aligned at the front or leading edge66 of statement 64. Statement 64 is directed by the input means to afirst pair of folder rollers 12a, 12b, which grab statement 64 anddirect it towards folder gate 16. When front edge 66 of statement 64comes into contact with folder gate 16, a buckle 68 is formed in thestatement 64 by the action of rollers 12a, 12b, and statement 64 isdirected through rollers 12b, 12c wherein statement 64 undergoesfolding.

As statement 64 passes between rollers 12b and 12c, it is foldedgenerally in half, as shown in FIG. 4B, so that statement 64 has afolded leading edge 70 and a protruding tail 72 due to the longer sheet64a (FIG. 4A). Statement 64 is passed along folder path 62 by folderrollers 12b, 12c, through rollers 12d, 12e, and towards kicker plate 40which is mounted on frame members 26a, 26b of the gate assembly of thesecond gate means. When the leading, folded edge 70 comes into contactwith kicker gate 40, further travel in that direction is prevented. Thestatement will stay in this position until kicker plate 40 is actuated,ejecting or pushing the statement into rollers 12e, 12f. Folder rollers12b, 12c, and 12d, which passively engage statement 64 along foldingpath 62, prevent statement 64 from being forced back up into thosefolder rollers.

Kicker plate 40 is actuated by actuator 42 under the direction of thecontrol means and according to the monitoring of the position ofstatement by the sensor means, as discussed below. Kicker plate 40 movesin a direction generally parallel to frame members 26a, 26b, and therange of the motion of kicker plate is shown in dashed lines in FIG. 3as well as FIG. 1. The action of kicker plate 40 pushes folded edge 70,which is now the trailing edge, and thereby ejects statement 64 throughfolder rollers 12e, 12f. During this process the protruding tail 72 isfolded over, preferably along a perforation 74, and then creased byfolder rollers 12e, 12f to provide a folded statement as shown generallyin FIG. 4D.

After ejection by kicker gate 40 and passing through folder rollers 12e,12f, statement 64 is folded as shown in FIG. 4E, with tail 72 generallyparallel to the remainder of statement 64, to provide a foldedconfiguration for statement 64 suitable for insertion into an envelope.

As related above, FIG. 2, FIG. 3, and FIG. 4A through FIG. 4E illustrateone of many possible folding operations which may be carried out withthe present invention. The aforementioned folding operation is shownwith sheets 64a, 64b (FIG. 4A) traveling along folding path 62 (FIG. 3)in a lengthwise manner, with shorter edges of sheets 64a, 64b serving asleading edges upon entering rollers 12a, 12b. However, in other possiblefolding schemes, the wider edges of sheets 64a, 64b could be the leadingedges upon entering folder rollers 12a, 12b. In further possible foldingscheme which may be carried out with the present invention, statement 64could, for example, be folded into thirds prior to the folding of tail70, rather than in half as shown in FIG. 3 and FIG. 4A through FIG. 4E,by appropriate positioning of the folder rollers 12a-12f, kicker plate40, and the gate means of the invention. While the gate means 32, 34shown in FIG. 1 through 3 are not used in the folding operation depictedin FIG. 3 and FIG. 4A through FIG. 4E, gate means 32, 34 may be used inother folding operations. Likewise, kicker gate 40, while shown asassociated with frame members 26a, 26b of the second gate means, mayalternatively be included with the second or third gate means 32, 34.

Referring now to FIG. 5, as well as FIG. 1 through FIG. 3, there isshown a flow diagram indicating a general control scheme for the foldingapparatus 10, to further illustrate the preferred manner of using theinvention. Generally, an input transport 100 is used to input statementsinto the folding apparatus 10. Input transport 100 preferably comprisesa conventional document transporting system as described above.

Control means, shown generally as system controller 110, directactuation of kicker gate 40 at the appropriate point in the foldingoperation, thereby avoiding unwanted folding of the tips of the shortersheets of the statements, as described above. Sensor means arepreferably interfaced with system controller 110 to allow detection andmonitoring of the location of statements within apparatus 10. The sensormeans is preferably in the form of shaft encoder 61, photoemitter andphotodetector 58a, 58b associated with input transport 100, andphotoemitter 60a and photodetector 60b associated with the output meansof the invention.

The system controller 110 tracks the position of statements 64 bymonitoring the encoder and sensors 120. Shaft encoder 61 providesrotational information regarding the machine cycle of the folderapparatus 10, which allows system controller to actuate kicker plate 130at the correct time. Sensors 58a, 58b are monitored 120 by systemcontroller 110 to verify that a statement 64 has entered foldingapparatus 10, and monitoring of sensors 60a, 60b similarly providesverification that statement 64 has cleared the apparatus 10. If astatement 64 has not properly entered or cleared the apparatus 10,system controller 110 is so notified, and may shut down operation of thefolder apparatus 10 and/or other mail processing operations to allow anoperator to search for paper jams or other problems to detect thelocation of statements in apparatus 10.

When shaft encoder 61 indicates to system controller 110 that astatement is correctly positioned along folding path 62 (FIG. 2), thesystem controller actuates the kicker plate 130, ejecting the foldedstatement through the final pair of rollers, which, in the illustrativeexample provided above, are folder rollers 12e, 12f.

Exit transport 140, which, as described above, is preferably a belt andpulley-type document transportation system, receives folded statementsfrom folder rollers 12a-12f. Sensor photoemitter and photodetector 60a,60b, are positioned adjacent exit transport 140, and verify thatstatement 64 has exited folder rollers 12a-12f, as related above. Exittransport 140 is generally interfaced with another mail statement ordocument processing system (not shown), such as an envelope insertionsystem.

Accordingly, it will be seen that the present invention provides afolding apparatus which quickly and effectively folds statements havingsheets of multiple lengths without causing additional, unwanted foldingof the tips of shorter sheets within the statement. Although the abovedescription contains many specificities, these should not be construedas limiting the scope of the invention, but as merely providingillustrations of some of the presently preferred embodiments. Thus, thescope of the invention should be determined by the appended claims, andtheir legal equivalents.

What is claimed is:
 1. A folding apparatus for simultaneously foldingthe entirety of a plurality of sheets, wherein a first sheet within theplurality of sheets having a perforation along a line and is longer thana second sheet within the plurality of sheets, comprising:a) a pluralityof roller means for folding the plurality of sheets, wherein saidplurality of roller means comprises:first, second, and third rollerswherein paired first and second said rollers actively engage and forcebuckling of the plurality of sheets and paired second and third saidrollers actively engage and fold the plurality of sheets; a forth rollerthat passively engages the plurality of sheets to prevent backup of theplurality of sheets and helps direct the plurality of sheets to pairedfifth and sixth rollers; and said paired fifth and sixth rollers whereinsaid paired fifth and sixth rollers actively engage and fold the firstsheet at the perforation line; b) at least one depth adjustable gatemeans for preventing further progression along a path of movement of theplurality of sheets including a fold at the perforation line of thelonger first sheet, wherein the plurality of sheets fits in said gatemeans without said plurality of roller means gripping the plurality ofsheets, said gate means adjacent to said fifth and sixth rollers of saidplurality of roller means and adjusted to have a depth that accepts thelonger first sheet; and c) means for ejecting folded sheets through oneof said plurality of roller means, thereby causing upon ejection saidfold at the perforation line of the longer first sheet, wherein saidmeans for ejecting immediately precedes said fifth and sixth rollers. 2.A folding apparatus according to claim 1, further comprising controlmeans for directing said ejecting means to eject upon completion of anoperation and includes sensor means to track and verify the position ofthe plurality of sheets relative to said ejecting means, wherein saidsensor means comprises:an encoder for timing said ejecting means basedon encoder determined rotational values for the folding apparatus and aplurality of photocell sensors located adjacent said roller means, saidgate means, and said ejecting means which track and verify the positionof the plurality of sheets during folding.
 3. A folding apparatus forsimultaneously folding the entirety of a plurality of sheets, wherein afirst sheet within the plurality of sheets having a perforation along aline and is longer than a second sheet within the plurality of sheets,comprising:a) a plurality of roller means for folding the plurality ofsheets, wherein said plurality of roller means comprises:first, second,and third rollers wherein paired first and second said rollers activelyengage and force buckling of the plurality of sheets and paired secondand third said rollers actively engage and fold the plurality of sheets;a forth roller that passively engages the plurality of sheets to preventbackup of the plurality of sheets and helps direct the plurality ofsheets to paired fifth and sixth rollers; and said paired fifth andsixth rollers wherein said paired fifth and sixth rollers activelyengage and fold the first sheet at the perforation line; b) a pluralityof gate means with at least one of said gate means being a depthadjustable gate means for preventing further progression along a path ofmovement of the plurality of sheets including a fold at the perforationline of the first sheet, wherein the plurality of sheets fits in saidgate means without said plurality of roller means gripping the pluralityof sheets, said gate means positioned adjacent said fifth and sixthrollers of said roller means and said depth adjustable gate meansadjusted to have a depth that accepts the longer first sheet; c) akicker plate, said kicker plate associated with at least one of saidgate means, said kicker plate positioned to push folded sheets throughsaid fifth and sixth rollers; and d) means for actuating said kickerplate, thereby causing upon being pushed through said fifth and sixthrollers said fold at the perforation line of the longer first sheet. 4.A folding apparatus according to claim 3, further comprising systemcontrol means for directing operation of said kicker plate to eject uponcompletion of an operation and includes sensor means to track and verifythe position of the plurality of sheets relative to said kicker plate,wherein said sensor means comprises:an encoder for timing said ejectingmeans based on encoder determined rotational values for the foldingapparatus and a plurality of photocell sensors located adjacent saidroller means, said gate means, and said ejecting means which track andverify the position of the plurality of sheets during folding.
 5. Afolding apparatus for simultaneously folding the entirety of a pluralityof sheets, wherein a first sheet within the plurality of sheets having aperforation along a line and is longer than a second sheet within theplurality of sheets, comprising:a) a plurality of folder rollers,wherein said plurality of folder rollers comprises:first, second, andthird rollers wherein paired first and second said rollers activelyengage and force buckling of the plurality of sheets and paired secondand third said rollers actively engage and fold the plurality of sheets;a forth roller that passively engages the plurality of sheets to preventbackup of the plurality of sheets and helps direct the plurality ofsheets to paired fifth and sixth rollers; and said paired fifth andsixth rollers wherein said paired fifth and sixth rollers activelyengage and fold the first sheet at the perforation line; b) at least onedepth adjustable folder gate for preventing further progression along apath of movement of the plurality of sheets including a fold at theperforation line of the longer first sheet, wherein the plurality ofsheets fits in said folder gate without said plurality of folder rollersgripping the plurality of sheets, said folder gate positioned adjacentsaid fifth and sixth rollers of said plurality of folder rollers andadjusted to have a depth that accepts the longer first sheet; c) akicker plate, said kicker plate associated with at least one said foldergates and positioned to push folded sheets through said fifth and sixthrollers; and d) an actuator, said actuator coupled to said kicker plate,whereby when said actuator is actuated, said kicker plate ejects saidplurality of sheets through said fifth and sixth rollers thereby foldingthe longer first sheet at the perforation line.
 6. A folding apparatusaccording to claim 5, further comprising a system controller computer,said system controller computer interfaced with said actuator whereinsaid system controller computer monitors by means of an encodermeasuring rotational positions in the folding apparatus and a pluralityof photocell sensors located adjacent said rollers, said gate, and saidkicker plate which track and verify the position of the plurality ofsheets during folding the plurality of sheets for location and activatessaid actuator at an appropriate time.